Storage system with robot device

ABSTRACT

A storage system for storing product items includes a grid structure and a number of first storage bins configured to be stored in vertical stacks in the grid structure. Each first storage bin is configured to contain at least one product item. A vehicle is arranged to move horizontally at the top level of the grid structure, and further arranged to pick up, carry, and place the first storage bins at desired locations within the grid structure. The storage system further comprises a robot device comprising a movable arm with a picking mechanism in one end thereof. The robot device is configured to move a storage item between a first location and a second location by means of its picking mechanism. The first location is the location of a first storage bin stored in the storage grid.

FIELD OF THE INVENTION

The present invention relates to a storage system.

BACKGROUND OF THE INVENTION

The Applicant's already known AutoStore system is a storage systemcomprising a three dimensional storage grid wherein storage bins arestacked on top of each other to a certain height.

The storage grid is constructed as aluminium columns interconnected bytop rails. A number of vehicles, or robot vehicles, are arranged on thetop rails and may move horizontally on top of the storage grid.

Each vehicle is equipped with a lift for picking up, carrying, andplacing bins that are stored in the storage grid.

The system also comprises delivery and/or supply stations, where one orseveral items are picked out from the storage bin or where one orseveral items are filled into the storage bin.

When an item of a product type stored in a storage bin is to beretrieved from the storage grid, the robot vehicle is arranged to pickup the storage bin containing that product type and then transport it toa bin lift device The bin lift device is transporting the storage bin tothe delivery and/or supply stations, where the item of the product typeis retrieved from the storage bin. The storage bin with the remainingitems of the product type is thereafter returned to the storage grid bymeans of a bin lift device and a robot vehicle.

The same procedure is used for refilling items into the storage grid.First, items are filled into a storage bin at a delivery and/or supplystation. The bin lift device is then lifting the storage bin up to theupper level where a robot vehicle is transporting the storage bin intoits correct position within the storage grid.

A storage control and communication system may be used to monitorinventory, location of storage bins (within storage grid and/or duringtransport), charge level, etc. The storage control and communicationsystem may also comprise, or may be provided in communication with, acontrol system for controlling the robot vehicles in order to avoidcollision.

It has been found that relatively long time is used by the storagesystem to transport storage bins from the top of the grid and to thedelivery and/or supply stations. Hence, one or more embodiments of theinvention provide a more time efficient storage system.

SUMMARY OF THE INVENTION

One or more embodiments of the present invention relates to a storagesystem for storing product items, comprising a grid structure, whereinthe grid structure has a top level. A number of first storage bins isconfigured to be stored in vertical stacks in the grid structure,wherein each first storage bin is configured to contain at least oneproduct item;

a vehicle, arranged to move horizontally at the top level of the gridstructure, and further arranged to pick up, carry, and place the firststorage bins at desired locations within the grid structure. Accordingto one or more embodiments of the present invention.

the storage system further comprises a robot device comprising a movablearm with a picking mechanism in one end thereof,

the robot device is configured to move a storage item between a firstlocation and a second location by means of its picking mechanism, and

the first location is the location of a first storage bin stored in thestorage grid.

It should be noted that even though each first storage bin is configuredto contain at least one product item, it is fully possible to storeempty first storage bins in the storage grid.

Aspects of the invention are apparent from the enclosed dependentclaims.

DETAILED DESCRIPTION

Embodiments of the invention will be described in the following withreference to the enclosed drawings, where:

FIG. 1 discloses a prior art storage system;

FIG. 2 illustrates schematically a side view of an embodiment of astorage system in accordance with one or more embodiments of theinvention;

FIG. 3 illustrates the embodiment in FIG. 2 from above;

FIG. 4 illustrates an alternative embodiment from above;

FIG. 5 illustrates yet another embodiment from above;

FIG. 6 illustrates a side view of the embodiment of FIG. 5;

FIG. 7 illustrates yet another embodiment from the side.

It is now referred to FIG. 1. Here it is shown a storage system 10comprising a grid structure 20 for storing products in storage bins 30.Each storage bin 30 is configured to contain one or several productitems.

As shown in FIG. 1, a certain number of the storage bins 30 areconfigured to be stored in vertical stacks within the grid structure 20.

A vehicle 40 is arranged to move horizontally at a top level L0 of thegrid structure 20, and further arranged to pick up, carry, and place thefirst storage bins 30 at desired locations.

The storage system 10 further comprises a delivery and/or supply station60. The delivery and/or supply station 60 is provided on the floor ofthe building onto which the storage grid 20 is arranged. This floorlevel is denoted Ln, where n is the number of storage bins 30 that canbe stacked in the storage grid 20. The delivery and/or supply station 60is used to prepare picked product items from the grid structure 20 fordelivery to a receiver (for example a buyer of a product item). Thedelivery and/or supply station 60 is also used to register product itemsfrom a supplier (for example a manufacturer of product items) beforeplacing the product items within the grid structure 20.

It should be noted that there may be several delivery and/or supplystations 60, and least one of these delivery and/or supply stations 60may be separated into delivery stations and supply stations, where thedelivery stations handle product items picked from the grid structureand where the supply stations handle product items to be placed into thegrid structure.

The system in FIG. 1 also comprises a bin lift device 50, arranged totransport the storage bins 30 between the top level L0 of the gridstructure 20 and the delivery and/or supply station 60. In FIG. 1 thistransport is shown in a vertical direction.

The storage system 10 shown in FIG. 1 is considered to be prior art.

In the following, the term “first storage bin” is used for the storagebins 30 stored in the grid structure 20 and which are to be transportedto the delivery and/or supply station 60 via the bin lift device 50.

First Embodiment—FIGS. 2 and 3

It is now referred to FIGS. 2 and 3. As in FIG. 1, the storage system 10comprises a storage grid 20 with stacks of storage bins 30. Levels L0,L1, L2-Ln are indicated.

The vehicle 40 is also shown. The particular vehicle 40 shown in FIG. 2is considered known. The prior art vehicle 40 may travel in thehorizontal direction (along a horizontal x-axis and a horizontal y-axisas indicated in FIG. 1) on level L0 of the grid structure 20. Thevehicle 40 comprises a lift (not shown) for picking up storage bins 30and for transporting the storage bins 30 to desired locations within thegrid structure 20 such as

-   -   from the grid structure 20 to a delivery and/or supply station        60 via bin lift device 50,    -   from the delivery and/or supply station 60 to the storage grid        20 via bin lift device 50,    -   internally within the grid structure 20.

For example, if a desired product item is located in a storage bin 30 atlevel L3, and below other storage bins 30, the vehicle 40 may first movethe upper storage bins 30 positioned directly above the storage bin 30to be picked (at levels L2 and L1) to other available locations on topof the grid structure in order to get access to the desired storage bin30 at level L3.

It should be noted that the particular design of the prior art vehicle40 shown in FIG. 2 renders temporary storage of storage bins 30 on levelL0 possible. In FIG. 2, it is shown a storage bin 30 at a location Alocated on level L0. Of course, this storage bin 30 at location A willprevent access to the storage bins directly beneath this storage bin.Moreover, the storage bin 30 at location A will also represent anobstacle to moving vehicles 40.

In FIG. 2 it is disclosed that the storage system 10 further comprises arobot device 70.

The robot device 70 comprises a base 71 connected to a movable arm 72.In FIG. 2, it is shown that the movable arm 72 comprises a first armsection 72 a connected to the base 71 and a second arm section 72 bconnected to the first arm section 72 a via a pivotal joint 72 c. Therobot device 70 further comprises a picking mechanism 74 at the outerend of the second arm section 72 b.

It should be noted that the robot device 70 itself is considered to beknown, as several such types of robots are commercially available.

In FIG. 2 it is shown that the base 71 of the robot device 70 is locatedat a distance above level L0.

The robot device 70 is configured to move a storage item 80 between afirst location A and a second location B by means of its pickingmechanism 74 (FIG. 3). In addition, the robot device 70 may beconfigured to move the entire first and/or second storage bin 30; 38 bymeans of its picking mechanism 74.

The robot device 70 may during use be located with its movable arm 72above a top level L0 of the storage grid 20 or at a level below the toplevel L0, for example level L1. Hence, the first location A may be thelocation of a first storage bin 30 stored at the top level L0 or at thelevel L1 directly below the top level L0 of the storage grid 20. Again,a storage bin 30 at level L1 is only accessible if there is no storagebin 30 at level L0 directly above it (at the same x- and y-location).

The robot device 70 is provided in communication with a vehicle controlsystem controlling the vehicles 40 in order to for example avoidcollision between the vehicles 40 and the robot device 70. It should benoted that there are several ways of achieving this—there may be onemain control system which controls the robot device 70 and each of thevehicles 40 in detail. For example, a main control system may define atime slot for vehicle movement within an area close to the robot device70, in which time slot the robot device 70 is instructed to move its armto a position where no collision may occur. Then, another time slot maybe defined in which the vehicles 40 are instructed to stay away from thearea close to the robot device 70. Alternatively, the control system maybe of a type where the robot device 70 and the vehicles 40 are more orless autonomous. For example, they may be equipped with sensorsconnected to an internal control system provided on each vehicle/robot40.

The above vehicle control system may be part of, or may be provided insignal communication with, a storage control and communication system asmentioned above.

In FIGS. 2 and 3, the first location A is the location of a firststorage bin 30 stored in or on the storage grid 20, while the secondlocation B is a location of a conveyor system generally referred to byreference number 90. The conveyor system 90 is arranged adjacent to thestorage grid 20. The second location B may be the location of a secondstorage bin 38 arranged on the conveyor system 90 as shown in FIGS. 2and 3 or indicate the location of the conveyor system 90 itself.

The conveyor system 90 may comprise one conveyor belt, conveyor chain orany other type of conveyors suitable for transporting a product item 80or a second storage bin 38 containing one or several storage items 80.The conveyor system 90 may also comprise several such conveyors.

The conveyor system 90 may be configured to transport the product item80 or the second storage bin 38 containing product items 80 to thedelivery and/or supply station 60, thereby acting as the robot lift 50mentioned earlier.

In FIG. 2, it is shown that the conveyor system 90 close to the robotdevice 70 is provided at a height Hc equal to, or above, a height HL1 ofthe level L1 directly below the top level L0. Of course, other parts ofthe conveyor system 90 may be located at lower heights.

One or more embodiments of the present invention makes it possible toincrease the efficiency of the storage system 10 by avoiding, entirelyor partially, the transportation of the first storage bins 30 to thedelivery and/or supply station 60 via the bin lift device 50.

Alternatively, one or more embodiments of the invention makes itpossible to arrange delivery and/or supply station(s) 60 at otherlevels, for example at a height corresponding to the height indicated inFIG. 2, and at a location in a room situated adjacent to the room inwhich the storage grid 20 is arranged.

As mentioned above, the first storage bins 30 have a design adapted forbeing stacked above each other in the grid structure 20 and for beingtransported by the vehicles 40 and the bin lift device 50.

However, the second storage bins 38 may also be of a different type. Thesecond storage bins 38 may be a cardboard box used for dispatching theproduct item(s) 80 to the receiver, for example the above mentionedbuyer of the product item(s) 80. Accordingly, the robot device 70 mayperform some or all of the working operations presently performed moreor less manually at the delivery and/or supply station 60. For sometypes of products, only the closing operation of the cardboard boxand/or the provision of an address label onto the cardboard box remain.

Alternatively, the second storage bins 38 are of substantially the sametype as the first storage bins 30, where the robot device 70 is pickingseveral of, or all of the product items of an order to one receiver. Thesecond storage bins 38 are then transported via the conveyor system 90to the delivery and/or supply station 60, where the order is finished byrepackaging the product items 80 from the second storage bin 38 into acardboard box. This may be necessary for product items 80 which requirespecial care, for example frangible product items 80. The operation isstill more efficient since all product items 80 of one order is arrivingat the delivery and/or supply station 60 at the same time.

It is once again referred to FIGS. 2 and 3. Here it is shown that theconveyor system 90 comprises a first conveyor 90 a transporting secondstorage bins 38 in a first direction (indicated by arrow x in FIG. 3)and three conveyors 90 b, 90 c, 90 d subsequently transporting storagebins 38 in parallel in a second direction (indicated by arrow y in FIG.3).

It is now referred to FIG. 3. Here, a first robot arm reachable area isindicated by a dashed box A1 in the grid structure 20 and a second robotarm reachable area is indicated by a dashed box B1 outside of the gridstructure 20. A product item 80 at location A is indicated within afirst storage bin 30 within area A1 and a location B for the productitem 80 is indicated within a second storage bin 38 within area B1. Asshown, the second area B1 is located on the three parallel conveyors 90b, 90 c, 90 d, close to the robot device 70.

In FIG. 3, the dashed circle C is indicating the maximum reach of thepicking mechanism 74 of the robot device 70. Of course, the number offirst storage bins 30 within the first area A1 and the number of secondstorage bins 38 within the second area B1 may vary based on the size ofthe robot device 70 and the size of the storage bins 30, 38.

Hence, the storage control and communication system is configured tocontrol the vehicles 40 to place a plurality of first storage bins 30within the first robot arm 72 reachable area A1 of the storage grid 20and then to control the robot device 70 to move the product item 80 fromat the first storage bin 30 in the first robot arm 72 reachable area A1of the storage grid 20 to the second storage bin 38 placed in the secondrobot arm 72 reachable area B1 outside of the storage grid 20.

When all product items 80 are placed into the second storage bin 38, thebin 38 is transported via the conveyor 90 b to the next station forfurther handling (dispatching, repackaging or other operations at thedelivery and/or supply station 60, etc). Empty second storage bins 38are supplied via conveyor 90 a, and the robot device 70 may move asecond storage bin 38 from the first conveyor 90 a to the free spacewithin the second area B1.

Alternatively, the conveyors 90 b, 90 c, 90 d may transport empty secondstorage bins 38 towards the robot device 70 (opposite direction of arrowy) and may move the second storage bins 38 with product items 80 ontothe first conveyor 90 a for further handling.

Alternatively, the robot device 70 is used to supply the storage grid 20with product items 80. Here, the storage bins 38 may arrive to the robotdevice 70 and the robot device 70 is used to fill first storage bins 30which then are moved into the desired location within the storage grid20 by means of the vehicles 40.

According to the first embodiment, the prior art bin lift device 50 maybe partially or entirely omitted in the storage system. This is highlyadvantageous since the bin lift device 50 in some prior art storagesystems may have a height of 5 meters or more, which in total consumes aconsiderable amount of the total transportation time. An omission of aprior art bin lift device 50 also have the potential of mitigatinglogistic problems related to for example efficient sorting of productitems 80.

Second Embodiment—FIG. 4

It is now referred to FIG. 4. The second embodiment has many features incommon with the first embodiment above, and the same reference numbershas been used for those common features. For efficiency, only thedifferences between the second and first embodiment are described here.

In the second embodiment, the conveyor system 90 comprising a firstconveyor 90 a and a second conveyor 90 b are arranged in parallel. Theymay move in the same direction or in opposite directions. As in FIG. 3the first robot arm reachable area A1 are indicated in the storage grid20 and second robot arm reachable area B1 are indicated on the first andsecond conveyor 90 a.

Third Embodiment—FIGS. 5 and 6

It is now referred to FIGS. 5 and 6. The third embodiment has manyfeatures in common with the first embodiment above, and the samereference numbers has been used for those common features. Forefficiency, only the differences between the third and first embodimentare described here.

In the third embodiment, the robot device 70 is fixed to the gridstructure 20 and can be surrounded by vertical stacks of storage bins30. Here, the conveyor system 90 is provided above, not on the side of,the storage grid 20. Moreover, the conveyor system 90 comprises only oneconveyor 90 a. In this way, also central parts of the storage grid 20can be within a robot arm reachable area. In FIG. 5 a first robot armreachable area A1 is indicated in the storage grid 20, and a secondrobot arm reachable area B1 is indicated on the conveyor 90 a.

According to one or more embodiments of the present invention, theconveyor system 90 is provided at a height HV corresponding to theheight of a vehicle 40 (see dashed line in FIG. 6) above the top levelL0. Hence, vehicles 40 may pass under the conveyor system 90.

Fourth Embodiment—FIG. 7

The base 71 of the robot device 79 is here supported by an iron girder,or supporting beam above the grid structure 20, such as a girder/beamsupporting the roof of the building under which the storage grid 20 isprovided. Such a robot device 79 may be fixed at one specific locationabove the grid structure 20, or be moveable by for example sliding onsaid girders/beams.

In such an embodiment, it is also possible to provide the conveyorsystem 90 with a conveyor 90 a at a height HV corresponding to or abovethe height of a vehicle 40, so that the vehicle 40 can pass under theconveyor belt. It is also possible to provide the conveyor system 90with a conveyor 90 b within the grid 20, for example at approximatelylevel L1 or L2.

It should be noted that the storage system 10, in all of the aboveembodiments, will be adapted to its intended use. The storage system 10may comprise one or several such robot devices 70. The robot devices 70may be provided on the side of the storage grid as in the first andsecond embodiments above, and/or integrated into the storage grid as inFIG. 5, or above the storage grid as in FIG. 6.

The storage control and communication system may also be configuredaccording to its intended use. It may for example be configured toanalyze a plurality of picking orders and then determine the mostfrequently demanded product items 80 from the picking orders. Based onthis, it may configure or control the vehicles 40 to place the firststorage bins 30 containing the most frequently demanded product items 80in the first area A1.

Moreover, the storage control and communication system may further beconfigured to control the robot device 70 to move product items 80 frommore than one first storage bin 30 in the first robot arm 72 reachablearea A1 of the storage grid 20 to at least one second storage bin 38placed in the second robot arm 72 reachable area B1 outside of thestorage grid 20. As described above, the robot device 70 will then beable to carry out a picking order entirely or partially and hence makethe picking operation more efficient.

In the preceding description, various aspects of the assembly accordingto one or more embodiments of the invention have been described. Forpurposes of explanation, specific numbers, systems and configurationswere set forth in order to provide a thorough understanding of thesystem and its workings. However, this description is not intended to beconstrued in a limiting sense. Various modifications and variations ofthe illustrative embodiment, as well as other embodiments of the system,which are apparent to persons skilled in the art to which the disclosedsubject matter pertains, are deemed to lie within the scope of thepresent invention.

The invention claimed is:
 1. A storage system for storing product items,comprising: a grid structure, wherein the grid structure has a toplevel; a number of first storage bins configured to be stored invertical stacks in the grid structure, wherein each first storage bin isconfigured to contain at least one product item; a vehicle, arranged tomove horizontally at the top level of the grid structure, and furtherarranged to pick up, carry, and place the first storage bins at desiredlocations within the grid structure; a robot device comprising: a basethat is fixed in position with respect to the grid structure and amovable arm, operably coupled to the base, with a picking mechanism inone end thereof, wherein the robot device is configured to move astorage item between a first location and a second location by means ofits picking mechanism, and a storage control and communication systemconfigured to: control the vehicles to place a plurality of firststorage bins in a first robot arm reachable area of the storage grid;and control the robot device to move the product item from at least onefirst storage bin in the first robot arm reachable area of the storagegrid to at least one second storage bin placed in a second robot armreachable area outside of the storage grid, wherein the first locationis the location of a first storage bin stored in the storage grid. 2.The storage system according to claim 1, wherein the storage control andcommunication system is further configured to: analyze a plurality ofpicking orders; determine the most frequently demanded product itemsfrom the picking orders; place the first storage bins containing themost frequently demanded product items in a first area.
 3. The storagesystem according to claim 1, wherein the storage control andcommunication system is further configured to: control the robot deviceto move product items from more than one first storage bin in the firstrobot arm reachable area of the storage grid to at least one secondstorage bin placed in the second robot arm reachable area outside of thestorage grid.
 4. The storage system according to claim 1, wherein therobot device is provided in communication with a vehicle control systemcontrolling the vehicles, in order to avoid collision between thevehicles and the robot device.
 5. The storage system according to claim1, wherein the robot device during use is located with its movable armabove a top level of the storage grid or a level directly below the toplevel.
 6. The storage system according to claim 5, wherein the robotdevice is provided in communication with a vehicle control systemcontrolling the vehicles, in order to avoid collision between thevehicles and the robot device.
 7. The storage system according to claim1, wherein the first location is the location of a first storage binstored at the top level or the level directly below the top level in thestorage grid.
 8. The storage system according to claim 7, wherein therobot device is provided in communication with a vehicle control systemcontrolling the vehicles, in order to avoid collision between thevehicles and the robot device.
 9. The storage system according to, claim1 wherein the robot device is configured to move the first and/or secondstorage bin by way of the picking mechanism.
 10. The storage systemaccording to claim 9, wherein the robot device is provided incommunication with a vehicle control system controlling the vehicles, inorder to avoid collision between the vehicles and the robot device. 11.The storage system according to claim 1, wherein the second location isthe location of a conveyor system arranged adjacent to the storage grid.12. The storage system according to claim 11, wherein the robot deviceis provided in communication with a vehicle control system controllingthe vehicles, in order to avoid collision between the vehicles and therobot device.
 13. The storage system according to claim 11, wherein theconveyor system is provided at a height equal to, or above, a height ofthe level directly below the top level.
 14. The storage system accordingto claim 13, wherein the robot device is provided in communication witha vehicle control system controlling the vehicles, in order to avoidcollision between the vehicles and the robot device.
 15. The storagesystem according to claim 11, wherein the conveyor system is configuredto transport the product item or the second storage bin containing theproduct item to a delivery and/or supply station.
 16. The storage systemaccording to claim 15, wherein the system comprises a bin lift device,arranged to transport the first storage bin in a vertical directionbetween the top level of the grid structure and the delivery and/orsupply station.
 17. The storage system according to claim 11, whereinthe second location is the location of a second storage bin arranged onthe conveyor system.
 18. The storage system according to claim 17,wherein the robot device is provided in communication with a vehiclecontrol system controlling the vehicles, in order to avoid collisionbetween the vehicles and the robot device.
 19. The storage systemaccording to claim 17, wherein the conveyor system is configured totransport the product item or the second storage bin containing theproduct item to a delivery and/or supply station.